U.S. patent application number 15/907665 was filed with the patent office on 2018-07-05 for resistive heater with temperature sensing power pins.
This patent application is currently assigned to Watlow Electric Manufacturing Company. The applicant listed for this patent is Watlow Electric Manufacturing Company. Invention is credited to William BOHLINGER, Jack REYNOLDS, Jake SPOOLER, Louis P. STEINHAUSER.
Application Number | 20180192474 15/907665 |
Document ID | / |
Family ID | 56137519 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180192474 |
Kind Code |
A1 |
REYNOLDS; Jack ; et
al. |
July 5, 2018 |
RESISTIVE HEATER WITH TEMPERATURE SENSING POWER PINS
Abstract
A heater system includes a heater and a controller. The heater
includes a first power pin made of a first conductive material, a
second power pin made of a second conductive material that is
dissimilar from the first conductive material, and a resistive
heating element having two ends and made of a material that is
different from the first and second conductive material of the
first and second power pins. The resistive heating element forms a
first junction with one end of the first power pin and a second
junction at its other and with the second power pin. The controller
is in communication with the power pins for measuring changes in
voltage at the first and second junctions to determine an average
temperature of the heater based on the changes in voltage.
Inventors: |
REYNOLDS; Jack; (Maryland
Heights, MO) ; STEINHAUSER; Louis P.; (St. Louis,
MO) ; SPOOLER; Jake; (Hannibal, MO) ;
BOHLINGER; William; (Winona, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Watlow Electric Manufacturing Company |
St. Louis |
MO |
US |
|
|
Assignee: |
Watlow Electric Manufacturing
Company
St. Louis
MO
|
Family ID: |
56137519 |
Appl. No.: |
15/907665 |
Filed: |
February 28, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14725537 |
May 29, 2015 |
|
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15907665 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H05B 3/54 20130101; H05B
1/0261 20130101; H05B 3/18 20130101; H05B 3/0014 20130101; H05B
3/06 20130101; H05B 3/48 20130101; H05B 2203/014 20130101; H05B
1/0202 20130101 |
International
Class: |
H05B 1/02 20060101
H05B001/02; H05B 3/18 20060101 H05B003/18; H05B 3/54 20060101
H05B003/54; H05B 3/48 20060101 H05B003/48; H05B 3/06 20060101
H05B003/06; H05B 3/00 20060101 H05B003/00 |
Claims
1. A heater system comprising: a heater comprising: a first power
pin made of a first conductive material; a second power pin made of
a second conductive material that is dissimilar from the first
conductive material; and a resistive heating element having two
ends and made of a material that is different from the first and
second conductive material of the first and second power pins, the
resistive heating element forming a first junction with one end of
the first power pin and a second junction at its other and with the
second power pin; and a controller in communication with the power
pins for measuring changes in voltage at the first and second
junctions to determine an average temperature of the heater based
on the changes in voltage.
2. The heater system according to claim 1 further comprising a
plurality of heaters connected in sequence, each heater having
first and second junctions for sensing the average temperature for
each of the heaters.
3. The heater system according to claim 2, wherein the first power
pin is a power supply pin and the second power pin is a power
return pin, and the power return pin is in electrical communication
with each of the heaters.
4. The heater system according to claim 1, wherein the controller
is configured to switch between a heating mode for directing power
to the resistive heating element and a measuring mode for measuring
the changes in voltage at the first and second junctions to
determine the average temperature.
5. The heater system according to claim 4, wherein no power is
supplied to the resistive heating element through the first and
second power pins during the measuring mode.
6. The heater system according to claim 4, further comprising a
switching device for switching the controller between the heating
mode and the measuring mode.
7. The heater system according to claim 1, wherein the controller
is configured to measure the changes in voltage at the first and
second junctions without interrupting power to the resistive
heating element.
8. The heater system according to claim 7, wherein the controller
measures the changes in voltage at the first and second junctions
at a zero crossing of an AC input power signal.
9. The heater system according to claim 7, further comprising a DC
power supply and a field effect transistor (FET) as a switching
device, wherein the changes in voltage are measured during an
off-period of the FET
10. A method of controlling at least one heater comprising: (a)
activating a heating mode to supply power to a power supply pin,
the power supply pin made of a first conductive material, and to
return the power through a power return pin, the power return pin
made of a conductive material that is dissimilar from the first
conductive material; (b) supplying power to the power supply pin,
to a resistive heating element having two ends and made of a
material that is different from the first and second conductive
materials of the power supply and return pins, the resistive
heating element forming a first junction at one end with the power
supply pin and a second junction at its other end with the power
return pin, and further supplying the power through the power
return pin; (c) measuring changes in voltage at the first and
second junctions to determine an average temperature of the heater;
(d) adjusting the power supplied to the heater as needed based on
the average temperature determined in step (c); and (e) repeating
steps (a) through (d).
11. The method according to claim 10 further comprising the steps
of: interrupting step (b) and switching to a measuring mode; and
switching back to the heating mode after step (c).
12. The method according to claim 10 further comprising the step of
comparing the average temperature determined at step (c) to a
predetermined limit in order to detect the presence of moisture
proximate the power supply and return pins.
13. The method according to claim 10 further comprising the step of
controlling a plurality of heaters by sequencing through steps (a)
through (d) for each heater in a predetermined sequence.
14. The method according to claim 10, wherein AC power supplied to
the heater is switched at or near a zero-cross of a power signal to
carry out step (c) to measure the changes in voltage and determine
the average temperature of the heater.
15. The method according to claim 10, wherein power supplied to the
heater is switched during an off-period of a FET in communication
with a DC power supply to carry out step (c) to measure the changes
in voltage and determine the average temperature of the heater.
16. A heater for use in fluid immersion heating comprising: a
heating portion configured for immersion into the fluid, the
heating portion comprising a plurality of resistive heating
elements; at least two non-heating portions contiguous with the
heating portion, each non-heating portion defining a length and
comprising a corresponding plurality of sets of power pins
electrically connected to the plurality of heating elements, each
set of power pins comprising: a first power pin made of a first
conductive material; and a second power pin made of a second
conductive material that is dissimilar from the first conductive
material of the first power pin, the first power pin being
electrically connected to the second power pin within the
non-heating portion to form a junction, and the second power pin
extending into the heating portion and being electrically connected
to the corresponding resistive heating element, the second power
pin defining a cross-sectional area that is larger than the
corresponding resistive heating element; at least two termination
portions contiguous with the non-heating portions, wherein the
plurality of first power pins exit the non-heating portions and
extend into the termination portions for electrical connection to
lead wires and a controller, wherein each of the resistive heating
elements are made of a material that is different from the first
and second conductive materials of the first and second power pins,
and wherein each of the junctions of the first power pin to the
second power pin is disposed at a different location along the
lengths of the non-heating portions in order to sense a level of
the fluid.
17. A heater system comprising: a plurality of heater cores
defining zones; a plurality of power pins extending through each of
the heater cores, wherein the power pins are made of different
conductive materials; and at least one jumper connected between two
of the plurality of power pins being made of dissimilar materials,
wherein the jumper is in communication with a controller to obtain
a temperature reading of the heater system proximate the
jumper.
18. The heater system according to claim 17, wherein the heater
cores are cartridge heaters.
19. The heater system according to claim 17, wherein the heater
cores each include a heater circuit, the heater circuits of the
plurality of heater cores being connected to different two of the
plurality of power pins.
20. The heater system according to claim 19, wherein the different
two of the plurality of power pins are made of dissimilar
materials.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a divisional application of U.S.
Ser. No. 14/725,537, filed on May 29, 2015, the entire disclosure
of which is incorporated herein by reference.
Field
[0002] The present disclosure relates to resistive heaters and to
temperature sensing devices such as thermocouples.
Background
[0003] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0004] Resistive heaters are used in a variety of applications to
provide heat to a target and/or environment. One type of resistive
heater known in the art is a cartridge heater, which generally
consists of a resistive wire heating element wound around a ceramic
core. A typical ceramic core defines two longitudinal bores with
power/terminal pins disposed therein. A first end of the resistive
wire is electrically connected to one power pin and the other end
of the resistive wire electrically connected to the other power
pin. This assembly is then inserted into a tubular metal sheath of
a larger diameter having an open end and a closed end, or two open
ends, thus creating an annular space between the sheath and the
resistive wire/core assembly. An insulative material, such as
magnesium oxide (MgO) or the like, is poured into the open end of
the sheath to fill the annular space between the resistive wire and
the inner surface of the sheath.
[0005] The open end of the sheath is sealed, for example by using a
potting compound and/or discrete sealing members. The entire
assembly is then compacted or compressed, as by swaging or by other
suitable process, to reduce the diameter of the sheath and to thus
compact and compress the MgO and to at least partially crush the
ceramic core so as to collapse the core about the pins to ensure
good electrical contact and thermal transfer. The compacted MgO
provides a relatively good heat transfer path between the heating
element and the sheath and it also electrically insulates the
sheath from the heating element.
[0006] In order to determine the proper temperature at which the
heaters should be operating, discrete temperature sensors, for
example thermocouples, are placed on or near the heater. Adding
discrete temperature sensors to the heater and its environment can
be costly and add complexity to the overall heating system.
SUMMARY
[0007] In one form, a heater system is provided, which includes a
heater and a controller. The heater includes a first power pin made
of a first conductive material, a second power pin made of a second
conductive material that is dissimilar from the first conductive
material, and a resistive heating element having two ends and made
of a material that is different from the first and second
conductive material of the first and second power pins. The
resistive heating element forms a first junction with one end of
the first power pin and a second junction at its other and with the
second power pin. The controller is in communication with the power
pins for measuring changes in voltage at the first and second
junctions to determine an average temperature of the heater based
on the changes in voltage.
[0008] In another form, a method of controlling at least one heater
is provided that comprises activating a heating mode to supply
power to a power supply pin, the power supply pin made of a first
conductive material, and to return the power through a power return
pin, the power return pin made of a conductive material that is
dissimilar from the first conductive material; supplying power to
the power supply pin, to a resistive heating element having two
ends and made of a material that is different from the first and
second conductive materials of the power supply and return pins,
the resistive heating element forming a first junction at one end
with the power supply pin and a second junction at its other end
with the power return pin, and further supplying the power through
the power return pin; measuring changes in voltage at the first and
second junctions to determine an average temperature of the heater;
and adjusting the power supplied to the heater as needed based on
the average temperature determined in step. In another form of this
method, the step of supplying power is interrupted and a step of
switching to a measuring mode is carried out to measure the changes
in voltage, followed by switching back to the heating mode.
[0009] In still another form, a heater for use in fluid immersion
heating is provided that comprises a heating portion configured for
immersion into the fluid, the heating portion comprising a
plurality of resistive heating elements. At least two non-heating
portions are contiguous with the heating portion, each non-heating
portion defining a length and comprising a corresponding plurality
of sets of power pins electrically connected to the plurality of
heating elements. Each set of power pins comprises a first power
pin made of a first conductive material and a second power pin made
of a second conductive material that is dissimilar from the first
conductive material of the first power pin. The first power pin is
electrically connected to the second power pin within the
non-heating portion to form a junction, and the second power pin
extends into the heating portion is electrically connected to the
corresponding resistive heating element. The second power pin
defines a cross-sectional area that is larger than the
corresponding resistive heating element. At least two termination
portions are contiguous with the non-heating portions, wherein the
plurality of first power pins exit the non-heating portions and
extend into the termination portions for electrical connection to
lead wires and a controller. In one form, each of the resistive
heating elements are made of a material that is different from the
first and second conductive materials of the first and second power
pins, and each of the junctions of the first power pin to the
second power pin is disposed at a different location along the
lengths of the non-heating portions in order to sense a level of
the fluid.
[0010] In still another form, a heater system includes a plurality
of heater cores defining zones, a plurality of power pins extending
through each of the heater cores, wherein the power pins are made
of different conductive materials, and at least one jumper
connected between two of the plurality of power pins being made of
dissimilar materials. The jumper is in communication with a
controller to obtain a temperature reading of the heater system
proximate the jumper.
[0011] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0012] In order that the disclosure may be well understood, there
will now be described various forms thereof, given by way of
example, reference being made to the accompanying drawings, in
which:
[0013] FIG. 1 is a side cross-sectional view of a resistive heater
with dual purpose power pins constructed in accordance with the
teachings of the present disclosure;
[0014] FIG. 2 is a perspective view of the resistive heater of FIG.
1 and a controller with lead wires constructed in accordance with
the teachings of the present disclosure;
[0015] FIG. 3 is a circuit diagram illustrating a switching circuit
and measurement circuit constructed in accordance with one form of
the present disclosure;
[0016] FIG. 4 is a side cross-sectional view of an alternate form
of the heater having a plurality of heating zones and constructed
in accordance with the teachings of the present disclosure;
[0017] FIG. 5 is a side elevational view of an alternate form of
the present disclosure illustrating a plurality of heaters
connected in sequence and constructed in accordance with the
teachings of the present disclosure;
[0018] FIG. 6 is a side cross-sectional view of another form of the
heater having a resistive element with a continuously variable
pitch and constructed in accordance with the teachings of the
present disclosure;
[0019] FIG. 7 is a side cross-sectional view of another form of the
heater having a resistive element with different pitches in a
plurality of heating zones and constructed in accordance with the
teachings of the present disclosure;
[0020] FIG. 8 is a side cross-sectional view of a heat exchanger
employing a heater and constructed in accordance with the teachings
of the present disclosure;
[0021] FIG. 9 is a side cross-sectional view illustrating a layered
heater employing the dual purpose power pins and constructed in
accordance with the teachings of the present disclosure;
[0022] FIG. 10 is a flow diagram illustrating a method in
accordance with the teachings of the present disclosure;
[0023] FIG. 11 is a perspective view of a heater for use in fluid
immersion heating and constructed in accordance with the teachings
of the present disclosure;
[0024] FIG. 12 is a side cross-sectional view of a portion of the
heater of FIG. 11 in accordance with the teachings of the present
disclosure;
[0025] FIG. 13 is a graph illustrating exemplary differences in
temperature at the various junctions of the heater of FIG. 10 in
accordance with the teachings of the present disclosure; and
[0026] FIG. 14 is a perspective view of another form of the present
disclosure having a plurality of heater cores in zones and
constructed in accordance with the teachings of the present
disclosure.
[0027] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
DETAILED DESCRIPTION
[0028] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features.
[0029] Referring to FIG. 1, a heater according to the teachings of
the present disclosure is illustrated and generally indicated by
reference numeral 20. The heater 20 in this form is a cartridge
heater, however, it should be understood that the teachings of the
present disclosure may be applied to other types of heaters as set
forth in greater detail below while remaining within the scope of
the present disclosure. As shown, the heater 20 comprises a
resistive heating element 22 having two end portions 24 and 26, and
the resistive heating element 22 is in the form of a metal wire,
such as a nichrome material by way of example. The resistive
heating element 22 is wound or disposed around a non-conductive
portion (or core in this form) 28. The core 28 defines a proximal
end 30 and a distal end 32 and further defines first and second
apertures 34 and 36 extending through at least the proximal end
30.
[0030] The heater 20 further comprises a first power pin 40 that is
made of a first conductive material and a second power pin 42 that
is made of a second conductive material that is dissimilar from the
first conductive material of the first power pin 40. Further, the
resistive heating element 22 is made of a material that is
different from the first and second conductive materials of the
first and second power pins 40, 42 and forms a first junction 50 at
end 24 with the first power pin 40 and a second junction 52 at its
other end 26 with the second power pin 42. Because the resistive
heating element 22 is a different material than the first power pin
40 at junction 50 and is a different material than the second power
pin 42 at junction 52, a thermocouple junction is effectively
formed and thus changes in voltage at the first and second
junctions 50, 52 are detected (as set forth in greater detail
below) to determine an average temperature of the heater 20 without
the use of a separate/discrete temperature sensor.
[0031] In one form, the resistive heating element 22 is a nichrome
material, the first power pin 40 is a Chromel.RTM. nickel alloy,
and the second power pin 42 is an Alumel.RTM. nickel alloy.
Alternately, the first power pin 40 could be iron, and the second
power 42 could be constantan. It should be appreciated by those
skilled in the art that any number of different materials and their
combinations can be used for the resistive heating element 22, the
first power pin 40, and the second power pin 42, as long as the
three materials are different and a thermocouple junction is
effectively formed at junctions 50 and 52. The materials described
herein are merely exemplary and thus should not be construed as
limiting the scope of the present disclosure.
[0032] In one application, the average temperature of the heater 20
may be used to detect the presence of moisture. If moisture is
detected, moisture management control algorithms can then be
implemented via a controller (described in greater detail below) in
order to remove the moisture in a controlled manner rather than
continuing to operate the heater 20 and a possible premature
failure.
[0033] As further shown, the heater 20 includes a sheath 60
surrounding the non-conductive portion 28 and a sealing member 62
disposed at the proximal end 30 of the non-conductive portion 28
and extending at least partially into the sheath 60 to complete the
heater assembly. Additionally, a dielectric fill material 64 is
disposed between the resistive heating element 22 and the sheath
60. Various constructions and further structural and electrical
details of cartridge heaters are set forth in greater detail in
U.S. Pat. Nos. 2,831,951 and 3,970,822, which are commonly assigned
with the present application and the contents of which are
incorporated herein by reference in their entirety. Therefore, it
should be understood that the form illustrated herein is merely
exemplary and should not be construed as limiting the scope of the
present disclosure.
[0034] Referring now to FIG. 2, the present disclosure further
includes a controller 70 in communication with the power pins 40,
42 and configured to measure changes in voltage at the first and
second junctions 50, 52. More specifically, the controller 70
measures millivolt (mV) changes at the junctions 50, 52 and then
uses these changes in voltage to calculate an average temperature
of the heater 20. In one form, the controller 70 measures changes
in voltage at the junctions 50, 52 without interrupting power to
the resistive heating element 22. This may be accomplished, for
example, by taking a reading at the zero crossing of an AC input
power signal. In another form, power is interrupted and the
controller 70 switches from a heating mode to a measuring mode to
measure the changes in voltage. Once the average temperature is
determined, the controller 70 switches back to the heating mode,
which is described in greater detail below. More specifically, in
one form, a triac is used to switch AC power to the heater 20, and
temperature information is gathered at or near the zero-cross of
the power signal. Other forms of AC switching devices may be
employed while remaining within the scope of the present
disclosure, and thus the use of a triac is merely exemplary and
should not be construed as limiting the scope of the present
disclosure.
[0035] Alternately, as shown in FIG. 3, a FET 72 is used as a
switching device and means of measuring voltage during an
off-period of the FET with a DC power supply. In one form, three
(3) relatively large resistors 73, 74, and 75 are used to form a
protective circuit for the measurement circuit 76. It should be
understood that this switching and measurement circuit is merely
exemplary and should not be construed as limiting the scope of the
present disclosure.
[0036] Referring back to FIG. 2, a pair of lead wires 80 are
connected to the first power pin 40 and the second power pin 42. In
one form, the lead wires 80 are both the same material such as, by
way of example, copper. The lead wires 80 are provided to reduce
the length of power pins needed to reach the controller 70, while
introducing another junction by virtue of the different materials
at junctions 82 and 84. In this form, in order for the controller
70 to determine which junction is being measured for changes in
voltage, signal wires 86 and 88 may be employed such that the
controller 70 switches between the signal wires 86 and 88 to
identify the junction being measured. Alternately, the signal wires
86 and 88 may be eliminated and the change in voltage across the
lead wire junctions 82 and 84 can be negligible or compensated
through software in the controller 70.
[0037] Referring now to FIG. 4, the teachings of the present
disclosure may also be applied to a heater 20' having a plurality
of zones 90, 92 and 94. Each of the zones includes its own set of
power pins 40', 42' and resistive heating element 22' as described
above (only one zone 90 is illustrated for purposes of clarity). In
one form of this multi-zone heater 20', the controller 70 (not
shown) would be in communication with the end portions 96, 98, and
100 of each of the zones in order to detect voltage changes and
thus determine an average temperature for that specific zone.
Alternately, the controller 70 could be in communication with only
the end portion 96 to determine the average temperature of the
heater 20' and whether or not moisture may be present as set forth
above. Although three (3) zones are shown, it should be understood
that any number of zones may be employed while remaining within the
scope of the present disclosure.
[0038] Turning now to FIG. 5, the teachings of the present
disclosure may also be applied to a plurality of separate heaters
100, 102, 104, 106, and 108, which may be cartridge heaters, and
which are connected in sequence as shown. Each heater comprises
first and second junctions of the dissimilar power pins to the
resistive heating element as shown and thus the average temperature
of each heater 100, 102, 104, 106, and 108 can be determined by a
controller 70 as set forth above. In another form, each of the
heaters 100, 102, 104, 106, and 108 has its own power supply pin
and a single power return pin is connected to all of the heaters in
order to reduce the complexity of this multiple heater embodiment.
In this form with cartridge heaters, each core would include
passageways to accommodate power supply pins for each successive
heater.
[0039] Referring now to FIGS. 6 and 7, a pitch of the resistive
heating element 110 may be varied in accordance with another form
of the present disclosure in order to provide a tailored heat
profile along the heater 120. In one form (FIG. 5), the resistive
heating element 110 defines a continuously variable pitch along its
length. More specifically, the resistive heating element 110 has a
continuously variable pitch with the ability to accommodate an
increasing or decreasing pitch P4-P9 on the immediately adjacent
next 360 degree coil loop. The continuously variable pitch of
resistive heating element 110 provides gradual changes in the flux
density of a heater surface (e.g., the surface of a sheath 112).
Although the principle of this continuously variable pitch is shown
as applied to a tubular heater having filled insulation 114, the
principles may also be applied to any type of heater, including
without limitation, the cartridge heater as set forth above.
Additionally, as set forth above, the first power pin 122 is made
of a first conductive material, the second power pin 124 is made of
a second conductive material that is dissimilar from the first
conductive material of the first power pin 122, while the resistive
heating element 110 is made of a material that is different from
the first and second conductive materials of the first and second
power pins 122, 124 so that changes in voltage at the first and
second junctions 126, 128 are detected to determine an average
temperature of the heater 120.
[0040] In another form (FIG. 7), the resistive heating element 130
has pitches P1, P2, and P3 in zones A, B, and C, respectively. P3
is greater than P1, and P1 is greater than P2. The resistive
heating element 130 has a constant pitch along the length of each
zone as shown. Similarly, the first power pin 132 is made of a
first conductive material, the second power pin 134 is made of a
second conductive material that is dissimilar from the first
conductive material of the first power pin 132, while the resistive
heating element 130 is made of a material that is different from
the first and second conductive materials of the first and second
power pins 132, 134 so that changes in voltage at the first and
second junctions 136, 138 are detected to determine an average
temperature of the heater 120.
[0041] Referring to FIG. 8, the heater and dual purpose power pins
as described herein have numerous applications, including by way of
example a heat exchanger 140. The heat exchanger 140 may include
one or a plurality of heating elements 142, and each of the heating
elements 142 may further include zones or variable pitch resistive
heating elements as illustrated and described above while remaining
within the scope of the present disclosure. It should be understood
that the application of a heat exchanger is merely exemplary and
that the teachings of the present disclosure may be employed in any
application in which heat is being provided while also requiring a
temperature measurement, whether that temperature be absolute or
for another environmental condition such as the presence of
moisture as set forth above.
[0042] As shown in FIG. 9, the teachings of the present disclosure
may also be applied to other types of heaters such as a layered
heater 150. Generally, the layered heater 150 includes a dielectric
layer 152 that is applied to a substrate 154, a resistive heating
layer 156 applied to the dielectric layer 152, and a protective
layer 158 applied over the resistive heating layer 156. A junction
160 is formed between one end of a trace the resistive layer 158
and a first lead wire 162 (only one end is shown for purposes of
clarity), and similarly a second junction is formed at another end,
and following the principles of the present disclosure as set forth
above, voltage changes at these junctions are detected in order to
determine the average temperature of the heater 150. Such layered
heaters are illustrated and described in greater detail in U.S.
Pat. No. 8,680,443, which is commonly assigned with the present
application and the contents of which are incorporated herein by
reference in their entirety.
[0043] Other types of heaters rather than, or in addition to the
cartridge, tubular, and layered heaters as set forth above may also
be employed according to the teachings of the present disclosure.
These additional types of heaters may include, by way of example, a
polymer heater, a flexible heater, heat trace, and a ceramic
heater. It should be understood that these types of heaters are
merely exemplary and should not be construed as limiting the scope
of the present disclosure.
[0044] Referring now to FIG. 10, a method of controlling at least
one heater in accordance with the teachings of the present
disclosure is shown. The method comprises the steps of:
[0045] (A) activating a heating mode to supply power to a power
supply pin, the power supply pin made of a first conductive
material, and to return the power through a power return pin, the
power return pin made of a conductive material that is dissimilar
from the first conductive material;
[0046] (B) supplying power to the power supply pin, to a resistive
heating element having two ends and made of a material that is
different from the first and second conductive materials of the
power supply and return pins, the resistive heating element forming
a first junction at one end with the power supply pin and a second
junction at its other end with the power return pin, and further
supplying the power through the power return pin;
[0047] (C) measuring changes in voltage at the first and second
junctions to determine an average temperature of the heater;
[0048] (D) adjusting the power supplied to the heater as needed
based on the average temperature determined in step (C); and
[0049] (E) repeating steps (A) through (D).
[0050] In another form of this method, as shown by the dashed
lines, step (B) is interrupted while the controller switches to a
measuring mode to measure the change in voltage, and then the
controller is switched back to the heating mode.
[0051] Yet another form of the present disclosure is shown in FIGS.
11-13, wherein a heater for use in fluid immersion heating is
illustrated and generally indicated by reference numeral 200. The
heater 200 comprises a heating portion 202 configured for immersion
into a fluid, the heating portion 202 comprising a plurality of
resistive heating elements 204, and at least two non-heating
portions 206, 208 contiguous with the heating portion 202 (only one
non-heating portion 206 is shown in FIG. 11). Each non-heating
portion 206, 208 defines a length and comprises a corresponding
plurality of sets of power pins electrically connected to the
plurality of heating elements 204. More specifically, each set of
power pins comprises a first power pin 212 made of a first
conductive material and a second power pin 214 made of a second
conductive material that is dissimilar from the first conductive
material of the first power pin 212. The first power pins 212 are
electrically connected to the second power pins 214 within the
non-heating portions 206, 208 to form junctions 220, 230, and 240.
As further shown, the second power pins 214 extend into the heating
portion 202 and are electrically connected to the corresponding
resistive heating elements 204. Further, the second power pins 214
define a cross-sectional area that is larger than the corresponding
resistive heating element 204 so as to not create another junction
or measureable amount of heat at the connection between the second
power pins 24 and the resistive heating elements 204.
[0052] As further shown, a termination portion 250 is contiguous
with the non-heating portion 206, and the plurality of first power
pins 212 exit the non-heating portion 206 and extend into the
termination portions 250 for electrical connection to lead wires
and a controller (not shown). Similar to the previous description,
each of the resistive heating elements 204 are made of a material
that is different from the first and second conductive materials of
the first and second power pins 212, 214, and wherein each of the
junctions 220, 230, and 240 of the first power pin 212 to the
second power pin 214 is disposed at a different location along the
lengths of the non-heating portions 206, 208. More specifically,
and by way of example, junction 220 is at a distance L1, junction
230 is at a distance L2, and junction 240 is at a distance L3.
[0053] As shown in FIG. 13, with temperature of the junctions 220,
230, and 240 over time "t," the junction 220 is submerged in the
fluid F, the junction 230 is submerged but not as deep in the
fluid, and the junction 240 is not submerged. Accordingly,
detecting changes in voltage at each of the junctions 220, 230, and
240 can provide an indication of the fluid level relative to the
heating portion 202. It is desirable, especially when the fluid is
oil in a cooking/fryer application, that the heating portion 202
not be exposed to air during operation so as to not cause a fire.
With the junctions 220, 230, and 240 according to the teachings of
the present disclosure, a controller can determine if the fluid
level is too close to the heating portion 202 and thus disconnect
power from the heater 200.
[0054] Although three (3) junctions 220, 230, and 240 are
illustrated in this example, it should be understood that any
number of junctions may be employed while remaining within the
scope of the present disclosure, provided that the junctions are
not in the heating portion 202.
[0055] Referring now to FIG. 14, yet another form of the present
disclosure includes a plurality of heater cores 300 arranged in
zones of a heater system 270 as shown. The heater cores 300 in this
exemplary form are cartridge heaters as described above, however,
it should be understood that other types of heaters as set forth
herein may also be employed. Accordingly, the cartridge heater
construction in this form of the present disclosure should not be
construed as limiting the scope of the present disclosure.
[0056] Each heater core 300 includes a plurality of power pins 301,
302, 303, 304, and 305 as shown. Similar to the forms described
above, the power pins are made of different conductive materials,
and more specifically, power pins 301, 304, and 305 are made of a
first conductive material, power pins 302, 303, and 306 are made of
a second conductive material that is dissimilar from the first
conductive material. As further shown, at least one jumper 320 is
connected between dissimilar power pins, and in this example, power
pin 301 and power pin 303, in order to obtain a temperature reading
proximate the location of the jumper 320. The jumper 320 may be,
for example, a lead wire or other conductive member sufficient to
obtain the millivolt signal indicative of temperature proximate the
location of the jumper 320, which is also in communication with the
controller 70 as illustrated and described above. Any number of
jumpers 320 may be used across dissimilar power pins, and another
location is illustrated at jumper 322 between power pin 303 and
power pin 305, between ZONE 3 and ZONE 4.
[0057] In this exemplary form, power pins 301, 303, and 305 are
neutral legs of heater circuits between adjacent power pins 302,
304, and 306, respectively. More specifically, a heater circuit in
ZONE 1 would be between power pins 301 and 302, with the resistive
heating element (e.g., element 22 shown in FIG. 1) between these
power pins. A heater circuit in ZONE 2 would be between power pins
303 and 304, with the resistive heating element between these two
power pins. Similarly, a heater circuit in ZONE 3 would be between
power pins 305 and 306, with the resistive heating element between
these two power pins. It should be understood that these heater
circuits are merely exemplary and are constructed according to the
teachings of a cartridge heater described above and with reference
to FIG. 1. Any number and configurations of heater circuits with
multiple heater cores 300 and zones may be employed while remaining
within the scope of the present disclosure. The illustration of
four (4) zones and a cartridge heater construction is merely
exemplary and it should be understood that the dissimilar power
pins and jumpers may be employed with other types of heaters and in
a different number and/or configuration of zones while remaining
within the scope of the present disclosure.
[0058] It should be noted that the disclosure is not limited to the
embodiment described and illustrated as examples. A large variety
of modifications have been described and more are part of the
knowledge of the person skilled in the art. These and further
modifications as well as any replacement by technical equivalents
may be added to the description and figures, without leaving the
scope of the protection of the disclosure and of the present
patent.
* * * * *